product lifecycle management (plm)egeplm.ege.edu.tr/wp-content/uploads/2016/05/prof_eigner.pdf ·...

An Introduction – Fundamentals and Basic Applications

Product Lifecycle Management (PLM)

University of Kaiserslautern, Germany

Institute for Virtual Product Engineering (VPE)

Professor Dr.-Ing. Martin Eigner

PLM Workshop EGE University Izmir | November 13th, 2014

University of Kaiserslautern

Professor Dr.-Ing. Martin Eigner University of Kaiserslautern

Institute for Virtual Product Engineering

Professor Dr.-Ing. Martin Eigner University of Kaiserslautern



1968 - 1971 Toolmaker

1971 - 1976 University of Karlsruhe (TH)

Studies in Mechanical Engineering

1977 - 1980 University of Karlsruhe (TH)

PhD Institute of Computer applications in design

1980 - 1985 Robert Bosch GmbH

Head of Department

1985 - 2003 Eigner & Partner GmbH, AG, Inc.

Solution Provider for e-Engineering Technologies

until 2001 chief executive office

until 2003: Chairman of the Board and CTO

Company sold to ORACLE

since 2003 EIGNER Engineering Consult

CV

since 1992 University of Karlsruhe (TH)

visiting professor

since 1999 TU Sofia | Bulgaria

visiting professor

since 2004 University of Kaiserslautern


TE

AC

HIN

G

Research Profile


Product Lifecycle Management

Product Data Management

Model-Based Systems Engineering

Interdisciplinary product modeling

Interdisciplinary process modeling

Information and communication technology

Sustainable product design

New internett based products and services

Human factors in product design

Engineering workplace of the future

Object of research is the field of Virtual Product Engineering.

The institute has proven expertise in the following fields:

The research in all the institute‘s competence

fields is highly application-oriented.

Product Lifecycle

Management

Internet of

Things and Services

Model-Based

Systems

Engineering

Interdisciplinary

Product

Modeling

Interdisciplinary

Process

Modeling

Information

and

Communication

Technology

2012.05.07 - UNITY Workshop.pptx

2012.05.07 - UNITY Workshop.pptx

Principles and Drivers for Changes are: Complexity More complex products

More complex processes

More interdisciplinary processes

More complex supply chains

More complex regulations

Massive complexity

and information overload

of the users

Product Lifecycle Management as the overall engineering

concept is based on the idea of

connecting knowledge and seeks

to provide the right information

at the right time in the

right context.

Why Product Lifecycle Management?

CM, ECR

ERM

Product Data (2D, 3D, Documents)

Physical Tests

Requirements Structure

Functions Structure

Product Structure

Simulation (CAE, FEM, etc.)

M-CAD, E-CAD, CASE etc.

CAM

Process Planning Supply Chain Suppliers

Customers

Tools Devices

Plant & Machinery

Customer Service MRO

Recycling

www

Internet

Complexity is the biggest challenge

“Today’s complexity is only expected to rise, and more

than half of CEOs doubt their ability to manage it.” IBM 2010 Global CEO Study: 1500 face-to-face interviews, Companies of all sizes across 60

countries, representing 33 industries. (IBM CEO study)

Whether IT or device-based, software-based applications continue to grow in size and complexity. Globally

distributed and diverse teams, outsourcing and supply chain dependencies lead to increased challenges in the

timely launch of competitive products and services.

Organizations struggle to balance agility

and complexity.

It’s not enough to manage development, the design process itself must become more

streamlined and efficient.

http://public.dhe.ibm.com/common/ssi/ecm/en/gbe03297usen/GBE03297USEN.PDF

http://public.dhe.ibm.com/common/ssi/ecm/en/gbe03297usen/GBE03297USEN.PDF

Product Lifecycle Management (Tr: ÜRÜN YAŞAM DÖNGÜSÜ YÖNETİMİ) is the administrative and managing backbone in product engineering

Vision of Product Lifecycle Management (PLM)

Mekanik

Elektronik

Yazılım

Servis

Dsip

lin

ler

Fizibilite Ürün

Planlama

Ürün

Tasarımı

Proses

Planlama Üretim Operasyonlar Geriönüşüm

Ürün Yaşam Döngüsü OEM

1st Tier

2nd Tier

… Source:

Eigner, M.; Stelzer, R. (2009): Product Lifecycle Management - Ein Leitfaden für Product

Development und Life Cycle Management, Springer, Berlin.

Sami, Sayer; Aydın Ülker (2014): ÜRÜN YAŞAM DÖNGÜSÜ YÖNETİMİ, in: MÜHENDİS VE

MAKİNA [To be published]

Product Lifecycle Management (PLM) Fundamentals and Basics of PLM

Selected PLM Extensions

Implementation of PLM

The Digital Product & Process Model (DPPM) in the center of IT solutions in engineering

The Digital Product & Process Model

The Digital Product and Process Model

Sales and Distribution

Product Development Process Planning and Production

Cooperation with customers and suppliers

Service and Maintenance

http://carpoint.msn.com/vip/Nissan/Xterra

Base Models of a Product Data Management (PDM) System

Base Models of a PDM System

Product Model (Objects, Attributes,Relationship)

Process Model (ECR, ECO,…..)

CM

CM = Configuration Model

Product Model (static component)

Connecting the product and document data (ISO 9001) Documents

Master and structure data (design view)

Classification

Process Model (dynamic component)

Connection product data and document with processes (ISO 9001) Änderungs- und Freigabewesen

Distribution of information

Data exchange

Configruation Model

Description of the full lifecycle on the basis of ISO 10007 Connecting the product and document data on the effectivity (modification

index and / or serial number)

Tracebility according ISO 26262, EN50128, DO178B

Base Models of a PDM System

PDM

Definition of „Product Model“:

Product Model and its Representation

Product models have the goal to map real products with their relevant information for the entire life cycle. As part of the product model concept of ISO 10303 STEP partial models for different technical applications (architecture, electrical / electronic, mechanical and plant engineering, etc.) and for the entire phases of the product life cycle can be defined.

Document

Article

Typical Representation of a Product Structure

Typical Representation of a Product Structure

Stückliste 4711 Gyrocopter

Pos Artikel# Menge Bezeichnung

1... 3528 1 Zusammenbau

2... 2420 1 L-Brücke

3... 2715 1 Axialverbindung

4... 8215 1 Rechtes Fahrwerk

.1.. 3313 2 Reifen

.2.. 3333 2 Felgen

.3... 3323 2 Bremsen

..1 2435 2 Bremsscheiben

..2 2436 2 Bremszylinder

.4.. 4698 1 Gelenkbügel

5... 8216 1 Linkes Fahrwerk

.1.. 3313 2 Reifen

.2.. 3333 2 Felgen

.3... 3323 2 Bremsen

..1 2435 2 Bremsscheiben

..2 2436 2 Bremszylinder

.4.. 4698 1 Gelenkbügel

Definition of „Processes“:

Process Model

Processes in this engineering environment are the images of technical and organizational business processes. We distinguish stable long-term processes, such as testing, release, modification, and distribution, which are usually described in the quality manual. These processes have legal implications, for example, product liability, the electronic signature and the originality of the document.

Most important processes for PDM/PLM: ER Engineering Release ECR Engineering Change Request ECO Engineering Change Order

In process

Under examination

Released

Representation of the Process Model

Representation of the Process Model

Definition „Configuration model":

Configuration Model

Combining the functions of the product and process model is obtained automatically a methodological framework (configuration model), which organizes all the information on the contents, status, or version. By applying these rules, relationships and control the effects of changes to the managed product are tracked automatically.

The model "knows" so: where each part is used who developed, manufactured and delivered it, who initiated a change and takes responsibility, when this change was made, when it run into the production and why this change was made.

Configuration Management as sum of product and process model

Configuration Management (CM)

Past

Document structure

Product structure

Today

Future

Additional part with documents

Additional Documt

Configurations

Definition „Product Data Management“ (PDM):

Product Data Management

PDM is the management of product and process model with the aim to create explicit and reproducible product configurations.

Product Data Management (PDM) is the management of product defining data (product model) along with the management of technical and organizational business processes (process model) both in the field of discrete manufacturing (automotive, aerospace, consumer goods) and in the field of non-discrete manufacturing (chemical plants, power stations, utility and facility management). Product and process management together allow for a seamless reconfiguration of any design or manufacturing states of a product at any point of its whole lifecycle (configuration model).

Typical Product Data Management (PDM) functions

Typical PDM Functions

Item Master and Structure

Product

Part

Module

Dcument Articlel

Vault

NC-Prog.

3D-Model

Drawings / Structure

Document Management Group Technique

Project Management

Product structure

Document Structure

Release/Change Management

Workflow-Management

besser !

ERP

CAx

DTP

Office

Integration

I/O Management

Viewing, Redlining, DMU

Data Replication Vault/ Archiv / Backup

Access Management

Serv

ice

s A

pp

likat

ion

Example - Java User Interface

PDM User Interface

Example - HTML User Interface

PDM User Interface

- - - PDM functions - - -

Product and Document Structure

Product and Document Structure

Document

Project

Article

The main objects in PDM systems are: Article (Parts, components, products)

Several product structures

(z. B. as designed / as build bill of materials)

Paper or DV produced documents, with or without

safety relavent file Management

Projects

Several relations are defined between the objects: Project - Article

Article - Article

Article - Document ...

Additional objects are available: Release and change requests and orders

Variants

customer specific objects ...

PDM Objects

All objects in PDM systems have entries for the creation and all changes

• have user-, role- or function-specific access rights

Additionally, applies for all major object they "know" their current status (e.g. in work, in examination, ...)

they can change the status accordingly the defined expiration process. There consistency and safety rules

are monitored. Optional functions can be initiated at the transitions (e.g. mail, data transmission, format

conversion, ...)

they can be versioned

they have a history, which "lifelong" lists and manages all state changes. Predecessors and successors as

well as the entire resume can be reproduced at any time

they can be marked and detailed with note papers

What does the managing of the objects means?

A Part

An assembly

A product

An Article can be

An article is usually described by one or more documents : CAD models (-> 2D and/or 3D)

Text documents, for example specifications,...

Calculation results and NC programs ....

Each article can be used in multiple parent articles

The bill of materials describes the connections between the articles. Also you can derive the uses

and subordinate structures from the BOM.

Articles and Bill of Materials (BOM)

Name

Arm_02

Arm_03

Arm_04

Kraft

20.50

40.00

50.50

Gewicht

32.0

37.7

53,0

Variantenliste

Variant kits / BOMs are represented by a article structure with variant placeholders

constitute a variety of similar products or components

vermeiden redundante Speicherung ähnlicher Stücklisten

A variant BOM contains the following entries : optional BOM positions

Variant placeholder

Fixed parts/components (Are always part

of the kit)

A variant placeholder represent several alternatives

the alternatives are managed in a corresponding variant list

individual attributes can be added to the variant list

Variant BOMs

28 < > MAN Truck & Bus AG Christoph Laber MAN-Baukasten 13.06.2012 EAA

Federungsart

Fahrerhaus (L+H)

Getriebe + Achsübersetzung

Fahrzeuglänge + Überhänge

Achsformel

Motorleistung

Zul. Gesamtgewicht

7-12t 13-26t 18-41t

Baureihe

TGL TGM TGS TGX TGS WW

Darstellung exemplarisch

Federung VA

Motor

Rahmenlängsträger

1. Vorderachse

Getriebe

Fahrerhaus

Rahmenquerträger

1. Hinterachse

Federung HA

Bausteine im Baukasten

(Komponentenvarianten)

Produktgliederung

als Struktur des Fahrzeugbaukastens

Merkmale zur Beschreibung der Bausteine des Fahrzeugbaukastens

(Bestellmöglichkeiten und Codes)

Fahrzeugbaukasten Produktstruktur und Stückliste (Prinzipdarstellung)


Federungsart

Fahrerhaus (L+H)



Achsformel

Motorleistung

Zul. Gesamtgewicht

7-12t 13-26t 18-41t

Baureihe


Kein gültiges Fahrerhaus für TGS

gewählt Darstellung exemplarisch

Federung VA

Motor

Rahmenlängsträger

1. Vorderachse

Getriebe

Fahrerhaus

Rahmenquerträger

1. Hinterachse

Federung HA



Produktgliederung






Federungsart

Fahrerhaus (L+H)



Achsformel

Motorleistung

Zul. Gesamtgewicht

7-12t 13-26t 18-41t

Baureihe


Darstellung exemplarisch

Federung VA

Motor

Rahmenlängsträger

1. Vorderachse

Getriebe

Fahrerhaus

Rahmenquerträger

1. Hinterachse

Federung HA



Produktgliederung





Several document types vary in their requirements all documents have common and different attributes

some standard documents are predefined

custom document types can be easily extended

The retrieval of documents is supported through powerful search mechanisms

through navigation of all objects and structures

by classification, keywords and full text retrieval

The input and output of documents is supported through powerful viewer and Redliner

by attaching Plott management systems

Documents can be assigned to any processes and folders Release and change management

Distribute management

Document Types and Functions

Name

Gear001

Gear003

Gear017

Diam.1

120.50

118.00

98.45

NoTeeth

64

62

56

Class GEAR

Objects in PDM systems can be classified

simple definition of classes and subclasses, e.g.connecting elements screws and hex screws

Object-oriented class structures are the basis for a simple classification scheme

any desired assignment of features (e.g. diameter) with inheritance to subclasses

assignment of characteristics in a simple list

each element can be classified in several classes

powerful search mechanisms

including bandwidth search

Retrieval of Solutions through Classifications

A resume contains: The possible states of a

specific object

The connection of these

objects

Company and object-specific

cycles must be possible

The resume is closely connected

to the version control

Definition of Processes

Create (Vers. 0)

Released

Inactive / Archive

In process

In change

examination (electronic)

examination (mechanical)

Create (Vers. 1)

In process

examination (electronic)

examination (mechanisch)

Status

Transition

Best Practice:

An assembly consists of parts which are connected together (position and structure)

Incompatible change (across assembly)

incompatible change

Change in shaft casing in the lever New version is not compatible

133_A_Lever 144_A_Lever 121_A_Shaft 151_A_Shaft

New shaft

in

in

Workflow management of PDM is supported by:

Engineering Change Requests (ECR) /

Engineering Change Orders (ECO)

Testing mechanisms for ECR / ECO

Folders to collect all the elements of a process

Attaching notes ("yellow list")

Distribution lists with demand and control options

Incoming and outgoing mail

Workflow Management


incompatible change

100_A_Valve

120_A_Valve block 130_A_Handle piece

131_A_Handle 133_A_Lever 132_A_Nut

t1 t

121_A_Shaft 123_A_Housing

Change in shaft housing in the lever New version is not compatible

Change in shaft necessary


incompatible change

100_A_Valve

120_A_Valve block 130_A_Handle piece

131_A_Lever 133_A_Lever 132_A_Nut

140_A_Handle piece

144_A_Lever

t1 t

121_A_Welle 123_A_Casing

Change in shaft casing in the lever New version is not compatible

Change in shaft necessary

100_B_Valve

replaced by an incompatible module

Assembly must be replaced

151_A_Shaft

150_A_Valve block

Configuration management (CM) is a core component of a PDM system and therefore also central

function module of PDM

The Configuration Management is based on Resume definitions(organisational process)

Information about the status of an object

The existence of different versions of an object

The so called "effectivity": identification of the current version of an object (for example a time frame, or a

serial number)

The history of an object which keeps and manages state changes

A powerful Configuration Management is the difference between a PDM system and a document

management system.

Configuration Management (CM)

Configuration

Configurationen

100_Valve_A

120_Valve block_A 130_Handle piece_A

133_Lever_A

100_Valve_B

t1 t2

151_Shaft_A

150_Valve block_A

121_Shaft_A

140_Handle piece_A

144_Lever_A

t<t1 t>=t1

Configuration n

When entering a time < t1 configuration n is "computed"

Configuration n+1

When entering a time >= t1 configuration n+1 is „computed“

- - - Product Lifecycle Management- - -

Product Lifecycle Management (PLM) vs. Product Data Management (PDM)

Product Lifecycle Management – An Introduction

Design Engineering

Process Engineering

Production Engineering

Maintenance, Repair & Overhaul

Product & Portfolio Planning

PLM

Product planning

Development Process planning

Production Operation Recycling Requirements

Customer

Supplier

PDM

Manufacturing Process Mgmt.)

Project / Program / Portfolio Mgmt

Cost / risk analysis

Master and structur

Product

Part

Assembly

Dcument Articlel vault

NC-Prog. 3D-Model

Drawings / structure

Dokumentmanagement Group technique

Product structure

Document structure

Effectivity

Configuration Mgmt.

ERP

CAx

DTP

Office

Integration Engineering Collaboration

Requirement Mgmt. After Sales / MRO Governance & Compliance

Workflow Management

better !

I/O Management

Viewing, Redlining,DMU

Data replication Vault/Archive/Backup

Access Management EAI

Collaboration

Typical PLM Functions Se

rvic

es

Ap

plik

atio

n

Product Lifecycle Management (PLM) Fundamentals and Basics of PLM

Selected PLM Extensions

Implementation of PLM

Product Lifecycle Management is the administrative and managing backbone in product engineering


Source: Eigner, M.; Stelzer, R. (2009): Product Lifecycle Management - Ein Leitfaden für Product Development und Life Cycle Management, Springer, Berlin.

Mechanics

Electronics

Software

Services

Dis

cip

lin

es

Requirements

Definition

Product

Concept (F/B/L)

Product

Design

Process

Planning Production Operation Recycling

Product Lifecycle

OEM

1st Tier

2nd Tier

…

upstream downstream Status

quo

MBSE

R, F, B, L

Integration

in Disciplines

Simulation

Testing

Integration

Process

Planning

MRO,

Services

MBSE: Model Based

Sytems Engineering

R,F,B,L: Requirements, Function.

Behavior, Logic

MRO: Maintenance, Repair,

Overhaul

Model Based Systems Engineering + PLM (mecPro²)

Mechanik

E/E

Software

Modellbildung und -analyse

Dienst-leistung

Physical Tests

Virtuelle Tests

Validation

Hybride Tests

(z.B. HIL) Mechanik

E/E

Software

System Model PLM Backbone

Simulation Model

CASE M-CAD E-CAD

R

Dicipline Specific Design

L

P

Requirements Engineering and Specification (Requirements, Functions and Behavior)

Logical System Design and

multiphysical Simulation

Targets

Disciplin Specific Detailling

F/B

CASE Model

System Model

E-CAD Model M-CAD Model

Simulation Model

Simuation

Testing

Requirements Definition

Product

Planning Design

Process Planning

Production

Service Lifecycle Management


MRO

Services

Internet of the Things and Services

Source: Schaeffler

IoS: The connected StreetScooter

StreetScooter Sensor Technology

30 installed sensors

conneted via C2C box

Real time connection

WLAN, UMTS or GPRS

transmission via XMPP

Current signals

53 signals car to cloud

3 signals cloud to car Source: Streetscooter and ThingWorx

Professor Dr.-Ing. Martin Eigner

Institute for Virtual Product Engineering (VPE)

Phone: (0631) 205-38 73 Gottlieb –Daimler-Str.

Fax: (0631) 205-38 72 Geb. 44-314

E-Mail: [email protected] D-67663 Kaiserslautern

Web: vpe.mv.uni-kl.de

Thank you for your kind attention!